Flanged reenforced paper article and process of making same



E 7 j f\ Aug. '2, I932. A. MOORE 1,870,062

FLANGED REENFQRCED PAPER ARTICLE AND PROCESS OF MAKING SAME Filed June22; 1926' ffi-sheets-sheet l I INVEN'ILOR /Jr///7y79/7 /%.a/ s

ATTORN Aug. 2, 1 932. 1,870,062

FLANGED REENFORCED PAPER ARTICLE AND PROCESS OF MAKING SAME A. MQOREFiled June 22, 1925 3 Sheets-Sheet; 2

' 'ITORNEY Aug. 2, 1932. A, M ORE 1,870,062

FLANGED REENFORCED PAPER ARTICLE AND PROCESS OF MAKING SAME Filed June22, 1926 3 $heets-Sheet s INVENT R 4/0777? more Patented A z, 1932Annnieron MOQBE, ornnw Yon FLAHGED BEENB'OBCED PAPER AND PBOGIESSOF'EAKING sum Application filed June m, use. semi, m3. 117,749.

. My invention relates to flanged, merginally reenforced paper articlesand the process of mehng same, one-piece paper articles.

a The one-piece flanged and reenforced'e'rticles of the presentinvention, made of paper or other fibrous materiel having peper like.

characteristics (ell of which are referred to for 'convenienceof exression as paper l),

10 are adapted for e wi e variety of uses, es,

. for example, they may themselves be made use of, with or Without asuitable cover, as

cups, plates, or'conteiners, or may be made use of as heads or ends orcovers for other conte teiners' also-made preferably of paper, or

they may serve various vother purposes.

The flanged margin of the paper disk (which is usually circular, but maybe of other forms) is flowed inwardly into multiple 2 folds endthemultiple ports may be peeked together under it very high pressure,for example, a pressure of about three to five tons per square inch,causing the multiple parts to be peeked strongly together, and 25 toprovide a very strong end liighly'coberent marginal ring ofsubstantially permnnent gage dimension, which impart-s greet strength tothe completed article,

The pecking pressure is applied in second 59 once with my invention in eplurality of directions, and in difi'erent engulerl;y relateddirect1onn,es,ior example,- in directions at right angles to oneanother. Preterebly, pecking pressure is applied on the end ot theiniolded flenged portion, which rnny be conveniently referred to esverticelly op plied, end in directions at right englee thereto, whichmay similarly be referred to as horizontal application or pressureseparate stages, in the directions referred to, e completeinterknittingend pecking oi the folds and fibers is obtained in the merginel flangedring, while the surfaces thereof are of high smoothness end finish, thusgiving high strength together with hendsome ep pearence. I

.While the; invention is ep liceble to pre viously flanged diets, the.angingof the disk is preferably included inthe process,

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and particularly to By applicationof pressure, preferably in at least insome forms of its application, and in the present disclosure the stepsinclude the formation of the flange on the disk or blank, as Well as thefabrication of the mom ginal infolded end peeked ring portion thereof. v

The multiple iniolding of the flanged disk involves peculiar dificulties'beceuse of the nature of the flanged material to be handled, In drawingthe flange there is e, reduction 641 in radius from that of the blankequal to the dept-hot the'flenge end, of course, we corresponding doublereduction in the diametera For example, in the case of 'meking e den euarticle, as e cup, three inches in diameter with e simple flangetivo'inches deep, the original blenk is about seven inches in diameter,and at the margin of the flange, stock heving en original diameter ofseven inches is compressed or shortened circumferentislly'to e dienieterof three inches;

When iienging is done without permittin Y a substantial increase inthickness, esis pretereble, materiel or the flange is naturally veryhighly compressed and smoothly celendered, particularly at end neer theedge of the flange remote from the central or base of the flanged on};so formed.-

A. flanged-cup so formed may hold. its shepe if used in this conditionand if nothing is done to it after simple fienging. It", however, it isettenipted'to turn the flange inwardly, as by means oi applying isspinning tool to the edge, the cohesion of the fibers, which former lyheld it, in the instance referred to, to s,

three inch diameter insteed of the original seven inch diameter, issubstantially releewd end is no longerefiective to holdthe fibrestogether, end, instead of spinning the flange inwardly in e reversetold, as may readily be done, tor exemple, with 'peper not proliminerilyflanged, the result of such opere tion is merelyto term the flangededgeinto whet meyjperheps best be referred to as e sort of rufie.Dificulties such es referred to ere disposed of in eceordence with thepresent invention end the release of cohesion about the edge of theflange is av .ided by fiQWiLI'F the fienged Well'inwardly substantiallysun we paper blanks of various'forms, it may be aplied with particularadvantage to a circular taneously about the entire margin of the flange.

Application of flowing means in this manner also secures the additionaladvantage that non-rotary, reciprocating-movement devices, in the natureof a. press, maybe utilized therefor instead of rotary spinningapparatus, and a considerable simplification of operation ob tained,with resulting increase in speed and decrease in cost of production.

While the invention may be practiced upon lank with substantiallyV-shaped notches havin inwardly directed. apices evenly spaced about itsperiphery. This is for the reason that when extra deep flanges aredrawn, having about the same thickness as the original thickness of thepaper, there sulting highmarginal compression above referred to as beingencountered in drawing the flange is likely to be so great as to resultin an embri ing of the paper at and near the edge of the nange, whichwill result in this part of the flange being so weak and brittle as toreadily break. This embrittling effect due to" unduly high compressionof an unduly great amount of paper stock is avoided and substantiallydeeper flanges of high coherence and strength obtained by drawing aflange from a blank notched in substantially the manner described,thereby obtaining a reduction in the amount of paper stock andconsequently oftheextent of its compression in the neighborhood of themargin of the flange. The invention may be carried out, however, withunnotched blanks, particularly where the depth of flange is materiallyless than the I maximum possible depth.

In the accompanying drawings I have illustrated a mode of performing theprocess of the present invention for production of illustrative forms 6fflanged and reenforced products a have illustrated such forms of produts, but it is to be understood that such showing is illustrative onlyand is not presented for limitation of the invention, which is of thescope defined in my claims.

In said drawings, Fig.1 is a part sideand part cross-sectional view of aone-piece flanged rim fabricated paper article. Fig. 2 is a plan view ofa notched blank. Fig. 3 is a section on line 3-3, Fig. 2. Fig. 4 is a:fragmentary section of apparatus for carrying out the process, showingthe blank inserted in position to be operated upon. Fig. 5 is asectional view of the apparatus of Fig. 4, showing the position of theparts in an intermediate stage of the drawingof the flange.

Figs. 6-9 .are further sectional views; in which Fig. 6 shows thedraw-ing of the simple flange completed, Fig. 7 shows the flowing of theflange, Fig. 8 shows the application of lateral pressure to the inturnedflange material, and Fig. 9 shows the completion of the reenforcedmarginal ring bg application of vertical pressure thereto. ig. 10 is asectional view showing a modification in which the flange margin isflowed into substantially a curl preliminary to the principal inflowingoperation. Fig. 11 is a sectional View showing how a preliminarilycurled flange may be flowed into multiple folds without bottom guiding.Fig. '12 is a view similar to Fig. 11 with the flowing ring fullydepressed. Fig. 13 is a view similar to Fig. 9, but with the multipleinflowed flange margin of Fig. 11. Fig. 14: shows a further modificationin which the multiple part margin is formed within a straight sidedflange wall, and Fig. l5 shows the product of packing the multiple partmargin of the flange shown in Fig. 14 when the packing operation iscompleted as in Fig. 9 or Fig. 13.

The paper blank is shown as provided with the evenly spaced peripheralnotches 12 having their apices directed inwardly. The inner angle at 14need not be a sharp angle, but may be more or less blunted or squaredoff to some advantage in the formation and upkeep bead and correspondinginterior groove 22, and with the flange 24. terminating in theinfoldedipacked annular marginal ring 26 of permanent gage dimension andhigh strength made up of three thicknesses of material. 28, 30 and 32,firmly knitted and packed together (see Fig. 9). The reenforced flange2-1 is shown as being formed with a smooth inner face 34, extendingthroughout the entire depth of flange including the reenforced marginalring part 26, which makes it well adapted for being used as a cover orhead (top or bottom) for a cylindrical container, and with the provisionof such smooth continuous inner face 34 there is an outward bevel 36 provided at the junction of the reenforccd rim part or ring 26 with thebody part or nonreenforced part 38 of the flange 24 below (this term,like the terms horizontal, vertical, etc., is used in the relativesense. as will be understood) the reenforced ring part 26. The toolsillustrated in Figs. 4-9 for carrying out the process are made forproduction of this particular product. With changes in the form of theproduct as may extensivol'v be made within my invention, there will. ofcourse, be corresponding changes in the form of tools, as shown, forexample. in Figs. 10 14, but the showing herein made is suflicicnt toillustrate the principle of the invention.

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ceiving the blank. properly centered therein. The table 48. and innercylindrical wall of die 40 meet in a rounded corner 51 to avoid breakageof the paper stock in the drav'w ing operation.

The undrawn paper stock is confined by the pressure backing plate 52 towhich pressure is applied, to hold the stock flat and keep it smoothduring the drawing operation. The pressure applied is not suificient toretard m'ateriallythe movement of the paper inwardly upon the table 48during the drawing operation, but pressure plate 52 is heldagainst'upward movement during the draw.- ing operation, as by itscarrying bar 53, so. that there can be no material movement in an upwarddirectionof the paper or parts thereof, which might prevent a smoothdrawing operation being obtained. The downward movement of the backingplate 52 is terminated by coming into contact with adjustable stopmeans, as the screws 54, which are set according to the stock used toputthe paper under suitable tension without actually clamping it, sothat it could not be moved inpaper cup between them. The under or re- 1and the downward drawing pressure heap turn the "annular bead 62 to makethe wardly during the drawing operation. Member 52 also serves as astripping plate. This function will be referred to later.

In the drawing operation, I preferably make use of dies for holding thebottom of the ceiving die is indicated by reference numeral 56 and themale die, which enters the interior of the cup by numeral 58 The cupbottom 10a is gripped between dies 56, 58', as, for example, die 56 mayoperate against a brake plied to male die 58 to move the cup bottom 10aand the receiving die 56 along with it.

Where the shallow cup. 16 is the article produced, dies 56. and. 58 areof suitable conformation therefor, receiving die 56 having an annulargroove 60 to produce the head 20, and die 58 having in groove 22,receiving die 56 having a marginal upwardly extending ring port'on' 64,the outer wall 66 whereof has a sliding fit within the female die 40 andthe interior wall whereof comprises the substantially cylindrical orslig tly flared ortion 68 to form the flange part 38 and t e beveledpart 70 to form the bevel 36. The male die 58 "s correspondingly shaped,but of sufliciently smaller dimension to receive the paper stock betweenit and the receiving die at the lower, part and between it and thefemale die 40 above the receiving die 56. The outer wall of male die58thus comprises the lower sub- 5 the application ;.'and the bore 76 of.pressure closely aboutthe main part of its wall, which issubstantl'allycylindrical and enters the female die with only the,

paper between them, is represented by numeral 72. Parts 68 and 72 arepreferably rovided with paper gripping surfaces, as,

or example, very fine screw threads 74 may be cut therein.

It will be read-1y understood from the foregoing how the blank is drawninto amp with a single thickness flange wall. The blank, which haspreferabl been previously impregnated with a suitable impregnationmaterial, such as paratline wax, for example, is initially placed ontable 48. with receiving die 56 under it and the male die 58 above it,

as shown in Fig. 4, and the pressure plate 52 being held down to preventdeformation of the skirt of the blank, power is applied to force maledie 58 downwardly, and the flange is drawn by longitudinal movement ofmale die 58, the. receiving die 56 being 'forced downwardly therewithagainst brak-: ing resistance or other suitable'resistance so as to gripbottom 10a of the cup as a whole and to press it into the form selected.The gripping surfaces 74 assist in distributing of the force-used in thedraw ing operation.

The depth of the tools is such that the upper edge 10d of the drawn cupcomes well below plate 52 when the receiving die 56 reaches the limit ofmovement and rests on ledgeafi (Fig. 6). J; The male die 58 may now bewithdrawn, plate 52 fitting 2 of male die 58 causes plate 52 to serve asa stripper plate upon upward retreating movement of'male die 58. r

The flanged cup is thus left in place as also the receiving die 56, andwhile the cup may be pulled upwardly-a shortdistance away from receivingdie 56 upon retreat of male die 58, it nevertheless is kept in placewithin female die40 by the combined resser and Y stripping plate 52, andif raise is pushed back down on receiving die 56 by the insertion of theexpanding male die now to be referred to. r

This expanding male die 80, Fig. 7 ,enters in contracted form within thefemale die 40 after male die 58 is withdrawn and within the paper cupand after'being moved downwardly until stopped by the cup bottom res't-fing on the receiving die 56, is expanded, (as by means of relativelymovable wedging surfaces, such as customarily used for the expanding ofexpansible male dies). When die 80 is expanded, the lower projectingparts 82 thereoii serves toclam'p part, 38 of the c p flange againstthecorresponding part 68 of repart 82 of die 80 serves as a guide tocontrol the turning of the flange during the fold flow ing operation. Anannular opening is left between the shank part 86 of die 80 and thefemale die for the insertion of the flowing die 90.

Said die 90 is of annular form to enter and fit in the space between thebore wall of female die 40 and the relatively reduced shank portion 86of the male expanding die 80, as shown in Fig. 7. The lower margin ofthe flowing ring or die 90 is transversely concaved onsubstantially thesemi-circular arc of a circle .as shown at 92 with a preferably sharpouter edge 94, where it comes against the female die 40. The thickness 0flowing ring 90 and of the space provided for its reception is somewhatgreater than the product of the paper thickness multiplied by the numberof folds to be formed to permit a relatively wide flowing action to takeplace. Upon the depression of flowing ring 90 and the shar edge 94getting in behind the margin of t e flange 10?), the flange 10b iscaused to travel or flow inwardly as indicated in dotted arrows at theupper part of Fig. 7, and as the flowing die 90 moves downwardly, theflange 10?) is turned or of the cohesion obtainedvin flanging may flowedinwardly, along'the curved surface 92 and finally, as it turnsdownwardly and encounters and is guided by the concave guiding wall 84of male expanding die 80, it is guided around upon itself and along theinner wall 36' of the beveled part 36 of the cup until the free edge 10dturns upwardly and the marginal part 100 is brought in between the foldparts 106 and 10f, and a triple relatively loose fold formed, about asshown in full lines in Fig. 7. Where the blank was initially notched,the walls of notches 12 are closed or practically closed together in theflanging operation as shown at-12a, Fig. 7,

and upon the formationof the triple fo'ld;

as described these out apart edges are tucked or folded into theinterior of the interfolded marginal part of the flange. Partial releasemanifest itself in a spreading or thickening of the stock, as indicatedby the thickening of parts 100 and 10; in Fig. 7, and the wider spacingand lightening of the hatch lines in these parts. U on the completionof' the triple fold, the owing die 90 is withdrawn and the expar dingmale die 80 is contracted to clear the infolded flange and withdrawn,and these ,withdrawal movements'may take 'place simultaneously orpractically so, if desired. H

The expansion plug 100, Fig.8, is then introduced in. contracted formand expanded. Said plug 100 when radially expanded has a cylindricalinner wall 102 adapted to form the smooth inner paper flange wall 34.Expansion ofplug 100 brings the parts of the triple folded flange intoapproximately their ultimate relation in the direction of thicknessofthe marginal flange, as shown in Fig. 8, and same are confined,exceptat the top, so that the triple folded flange upon being compressedlaterally by expansion of expansible plug 100, as indicated in Fig. 8,may

expand upwardly to some extent as is also indicated in this view.

The annular packing ring 110 is now depressed to engage thetriple foldedflange at the only previously unconfined part, namely, the top thereof,and by application of exceedingl high consolidatin pressure thereon,thetrip e folded margin 0 the flange is packed or consolidated togetherinto the form shown in Figs. 1 and 9, and upon being so packed orconsolidated the finished product will retain substantially its fixedgage dimensions upon removal from the formingdies.

While the exterior-of the packed ring 26 is of a High degree ofcalendering and smoothness, it would be found, as upon dissection,

.that in the interior the fold lines have prachard wood or ivory ratherthan ordinary paper, and the resulting reenforced flanged disk cover,cup or the like is a permanently dimensioned product of high utility forthe various uses to which it is to be put, some instances of which havebeen referred to above,

\Vhen the packing operation is completed as described, the packing ring110 and plug are withdrawn, the latter being-first contracted, and theproduct 16 discharged by the receiving die 56 being moved. upwardly tothe position of Fig. 4. ready to receive a new blank, and the operationis repeated indefinitely, and may be carried on with the utmostrapidity, since substantially only rectilinear movement of working partsis involved.

When the blank or flanged disk has been impregnated with suitableimpregnating material having cementitious and lubricating qualities,such as parafline wax, for example,

which may be done with considerable advantage in facilitating the'flangeflowing opera- -tion, such impregnation material even if conof theflange edge prior to folding by flowing,

' the parts will not be properly flowed into folds, but will tend towrinkle together or pile up on one anotherwith resulting loss ofstrength, and it is, therefore, essential that all buckling'oif theflange edge is to be avoided.

In Figs. -141 have shown how by initially curling the margin of theflange, as

indicated at 120, 'a packed flangering may be the steps alreadydescribed with respect to Figs. 1-9, but is of especial utility wherethe expanding male die 8011, as shown in Figs. 11 and 12 lacks therounded guiding portion 84 already described, and is' of otherformation,

as, for example, is formed with the extension part 82a projectingsquarely from the shank 86a of die 80a, instead of having the filletedor rounded guiding portion 8 Shown in I 1 structures shown and the toolsfor their Fig. 7.. g

Fig. 10 illustrates the formation of the Preliminary ,margin curl 120 inthe paper flangeby means of a curling ring or die 122 having arelativelyshort-radius farcuate curling groove 123 formed in theunderface thereof. After being moved downward to a su'ficient extent toflow the free edge 10d along such radius into contact with orsubstantially into contact: with the body portion 126 of the flange 128,the curling die 122 may retreat, leaving the flange 128 with themarginal cur1.120., 1

By substantially replacingthe free edge oi the fian e ,128 with a shortradius marginal curl are further inflowing operation is tlyfacilitatedand on applying the flowmg die 130 (Fig. 11) with thelarger radiusgroove 132 the stock is naturally, so to speak, owed into practically asmany turns as ma be desired and this without reliance on roun edguldingsuriaces or the male die, such as shown at 84, Fig. 7.

When the flowing die130 is brought down 'as :Ear as it will go,- aformation such as shown in Fig. '12 can be produced with a veryconsiderable number of folds or turns, six parts being shown in Fig, 12.V The insertion.(contracted) and expansion of expansible male die 10,0amay operate to turn the folded parts backwardly to some extent, andthere may be a small reduction in the number of parts'forming the finalpacked ring when the maledie'IOOa has been expanded to compress theparts laterally, and

.the final high packing pressure applied by the packing die 110a. Fig,13 shows such a reduction in number or parts from the five parts of Fig.11 down to four parts in Fig.

, 13, in which the final paclredring 134 com" prises a firmlyconsolidated four-pl structure made 11 of the parts designated as 136,138, 140 an 142, though it will be understood. that the separate pliesare so y related directions to t flange.

knit together as to form a coherent-solid mass with the fibers sointerknit together thatit is Very ditficult indeed to separate the plies1 or to distinguish them one, from another.

In Figs. 1-13 I have illustrated a double drawn flange with a smallerdiameter part adjacent to the cup bottom, and a larger diameter partincluding the margin 1002. If desired, however, the flange may be drawnwith a smooth, one-diameter outer wall as ously modified, as will beunderstood. 1

It will be understood that the particular formation are illustrativemerely and that flanged articles of great variation in form, depth andthe like may be produced without departing from my invention.

I claim:

1. .In the ginally reen simultaneously inflowing' the flange margin allthe way around into a multiple ply fold process of making flanged,marorced paper articles, the step of co posed entirely of material ofthe flange.

2. In the process of makin flanged, marginally reenforcedpaper articles,the steps of inflowing the flange margin into a multiple fold composedentirely of material of the a flange, and with theraw flange edgeinsubstantiallthe middle of the foldiland consolidating't e infoldedapplication of consoli 3. In the process of making ginally reemforcedpaper art as, the steps of inflowing the flange margin into a multipleparts of t e flange by ating pressure thereto.

flanged, marfold composed entirely of materialof the,

flangegand with. the originally raw flange edge inside the fold, andapplying packing pressure in a pluraliti of di' erent angularly 4.In'the process of making flanged, marginally reeniorced 'paper'articles, the steps of infolding the flange margin simultaneously allthe way around nto a multiple fold composed entirely of material of theflange, and with the raw flange edge inside the folds, applying pressureto and confining the folded parts laterall and applying packing pressurein a rig t line to the olded and confined arts at the edge thereof. 7 v

5. n the process of making flanged, marginally reenforced paper artcles, the steps of flowing the flange margin inwardly si- 'multaneouslyall the way round and guiding the edge thereof so that same is folded inand interposed directly between the flange e intolded parts of the walland an inturned part formed from the original flange wall.

6. In the process of making flanged, marginally reenforced paperarticles the steps 5 of applying flowing pressure to he flange marginsimultaneously all the way round and guiding the edge thereof inwardly,downwardly and upwardly and outwardly, so that a multiple ply fold isproduced composed entirely of material of the flange, and with the partoriginally formin the raw edge of the flange inside between t e flangewall and an inturned portion thereof.

7. In the rocess of making flanged, marfiinally reenibrced paperarticles, the steps of owing the flange margin inwardly simultaneouslyall the way round while dguiding the edge thereof so that same is leupwardly between the flange wall and an inturned part 20 thereof and atriple fold is formed com entirely of material of the flange, app ying'ressure to and confining the folded portion aterally, and applyingpacking ressure to the folded and confined parts a the edge thereof,whereby a closely packed, highly co" herent marginal ring of permanentgage dimension and high strength is reduced. 8. The process of making aeeply flanged marginal reenforced article of paper, which consists informing a blank with substantially V-shaped notches substantially evenlyspaced about the periphery thereof, drawing a deep flange on and b ank,whereby the 1 notches are substantially closed, infoldin the margin intoa triple fold with the notche or incised (part between the flange walland an inturne part thereof, and su jecting the folded ortion to packinpressure on all sides, w ereby a marginar1ng is obtained of highstrength and coherence with the incised parts of the blanksubstantiallyv enclosed within the interior of the marginal ring. '9. Inthe process of drawin a flange on a pager blank, the step of clampingthe central rawn parts between opposing members while drawing'theflangeat the marginal part. 7

g 10. In the process of making flanged marginallyfolded paper articles,the steps 01 curling the flange margin on a relatively small radiusfollowe by flowin it into multiple folds com osed entirely 0 material ofthe flange, an on a radius larger than used in curling the flange mar Intestimony whereo%: I have signed my I name hereto.

ARLINGTON

